The device, system and process of the present invention greatly reduces the time and space necessary to assemble a wire harness enables efficient manufacture of wire harnesses. The present invention comprises at least a wire viewer module, a machine vision and optical character recognition module, a cassette tray platform, designed to receive and hold in place a cassette tray, having one or more receptacles designed to receive and hold in place a wire harness connector, having multiple pin-hole cavities illuminated from below or behind by a light source mounted on a two-axis translation stage or gantry to identify a cavity for wire insertion. Moreover, the present invention may further comprise a portable, computer-implemented system capable of executing a series of automated process steps designed to identify wire markings and guide the error-free insertion of identified wires into wire harness connector pin-hole receptacles for assembly of a wire harness.

An I/O connector assembly configured for making a cabled connection to an interior portion of a printed circuit board for at least some signals passing through the I/O connector. The I/O connector assembly may be assembled by mounting a cage to a printed circuit board. A receptacle connector, including cables extending from a rear of the connector, may be inserted through an opening in the top or rear of the cage. The receptacle connector may be positioned in the cage by at least one retention member on the cage. A plug, mating to the receptacle connector, also may be positioned by a retention member on the cage. Positioning both the plug and receptacle relative to the cage reduces the tolerance stackup of the assembly and enables the connectors to be designed with shorter wipe length, which enables higher frequency operation.

A high-performance single barrel power connector for receiving electric power may be capable of receiving more than 330 W up to approximately 600 W of power. The V+ pin and V− pin may each be configured with a large plurality of contact points for connecting to a power plug. A connector body retaining the V+ pin and V− pin may configured with openings to expose more of the V+ pin and V− pin to air and allow the V+ pin and V− pin to extend out of the power connector for convective and conductive heat transfer. A shell having a high thermal conductivity may be connected to the V− pin and V− pin and further connected to a bracket for increased heat transfer away from the V+ and V− pins.

A high-performance single barrel power connector for receiving electric power may be capable of receiving more than 330 W up to approximately 600 W of power. The V+ pin and V− pin may each be configured with a large plurality of contact points for connecting to a power plug. A connector body retaining the V+ pin and V− pin may configured with openings to expose more of the V+ pin and V− pin to air and allow the V+ pin and V− pin to extend out of the power connector for convective and conductive heat transfer. A shell having a high thermal conductivity may be connected to the V− pin and V− pin and further connected to a bracket for increased heat transfer away from the V+ and V− pins.

Provided is a connector-mounted board manufacturing method for manufacturing a connector-mounted board, the connector-mounted board including a circuit board, on which a terminal and an electronic component are mounted, and a connector housing attached to the terminal. The connector-mounted board manufacturing method includes: executing a mounting process of mounting the terminal and the electronic component on the circuit board; and executing an attaching process of attaching the connector housing to the terminal after the mounting process has been executed.

A direct mate orthogonal connector for a high density of high speed signals. The connector may include right angle leadframe assemblies with signal conductive elements and ground shields held by a leadframe housing. The leadframe assemblies may each have signal mating ends extending from the signal conductive elements and ground mating ends extending from the ground shield. High frequency performance may be achieved with features on the leadframe housing and on the ground shield. The features may be simple to form yet ensure the positional relationship between the contacts points of the ground mating ends and the contact points of the signal mating ends to sustain forces generated during operating the connector to mate with another connector and/or mount to a board.

A direct mate orthogonal connector for a high density of high speed signals. The connector may include right angle leadframe assemblies with signal conductive elements and ground shields held by a leadframe housing. The leadframe assemblies may each have signal mating ends extending from the signal conductive elements and ground mating ends extending from the ground shield. High frequency performance may be achieved with features on the leadframe housing and on the ground shield. The features may be simple to form yet ensure the positional relationship between the contacts points of the ground mating ends and the contact points of the signal mating ends to sustain forces generated during operating the connector to mate with another connector and/or mount to a board.

A method of manufacturing a hermetic lead connector includes fixing an electrically insulating ring between an electrically conducting contact ring and an electrically conducting spacer ring to form a hermetic ring subassembly, and fixing a plurality of the hermetic ring subassemblies in axial alignment to form a hermetic lead connector. The hermetic lead connector includes an open end, an outer surface, and an inner surface defining a lead aperture. The hermetic lead connector provides a hermetic seal between the outer surface and the inner surface.

A method of manufacturing a hermetic lead connector includes fixing an electrically insulating ring between an electrically conducting contact ring and an electrically conducting spacer ring to form a hermetic ring subassembly, and fixing a plurality of the hermetic ring subassemblies in axial alignment to form a hermetic lead connector. The hermetic lead connector includes an open end, an outer surface, and an inner surface defining a lead aperture. The hermetic lead connector provides a hermetic seal between the outer surface and the inner surface.

A dual cable alignment apparatus (10) for rotationally aligning assembled cable ends of two cables (3,4) of a twisted cable harness (2), the cable alignment apparatus (10) comprising two clamping jaws (7,8) and a central web (9) disposed between the clamping jaws (7,8). Each of the two clamping jaws (7,8), which can be moved towards one another in the closing direction (s), can clamp a cable (3,4) between the central web (9) and the clamping jaws (7,8). The clamping jaws (7,8) are further designed to be movable laterally past the central web (9) for changing the rotational position by rolling the cable (3,4) clamped between them. The clamping jaws (7,8) can be moved independently of one another in the lateral direction by means of their own lateral drives (16,17), ensuring that each cable (3,4) can be brought precisely and reliably into the desired rotational position.